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The Medium Carbon Steel Tip Tap is a specialized tool designed for threading cold-work tool steel (D2, A2) and gray cast iron (ASTM A48 Class 30). Its unique cutting geometry—featuring a modified rake angle (14°) and reduced land width (0.15× pitch)—is the result of finite element analysis (FEA) simulations to address the challenges of machining hard, brittle materials. Constructed from 5140 medium carbon steel (quenched to HRC 58–62 via oil cooling), it balances hardness and toughness for precision threading in tooling applications, with a fracture toughness of 12–15 MPa·m⊃1;/⊃2;.
Optimized Cutting Edge: Micro-grain carbide inserts (grain size 0.8–1.2μm) with a TiCN coating are brazed to the cutting edge using induction heating (1050°C). This enhances wear resistance in D2 steel (HRC 55–60) by 50% compared to uncoated edges.
Medium Carbon Steel Construction: Core material provides 1200 MPa tensile strength with 15% elongation, resisting fracture during interrupted cuts in cast iron with graphite flake sizes (ASTM A247) of 5–7.
Precision Thread Form: Conforms to ISO 965-1 Class 5G, ensuring interchangeability with standard tooling components (e.g., die sets with H7 tolerance bores, fixture plates with positional accuracy ±0.02mm).
Primary uses include threading injection mold cavities (P20 tool steel with surface finish Ra ≤0.8μm), engine block mounting holes (gray cast iron with 3.2–3.6% carbon content), and press tool guides (A2 steel with through-hardening). It is a staple in tool & die shops adhering to ISO 9001 manufacturing standards, where thread concentricity (≤0.03mm TIR) is critical for mold alignment.
Q: How to prevent chip breakage in cast iron?
A: Use dry machining or minimal coolant (5–10 mL/min); cast iron’s graphite content acts as a natural lubricant. For nodular cast iron (ASTM A536 60-40-18), increase feed rate by 10% to promote continuous chip formation.
Q: What is the maximum thread depth for tool steel?
A: 2× diameter for HRC 55+ material (e.g., 16mm depth for M8 tap); deeper threads require step tapping with 0.5mm incremental depth per pass to reduce cutting forces.
Q: Does it require pre-drilling?
A: Yes, use a drill bit sized to 85% of the tap diameter (e.g., 6.8mm for M8) with a 118° point angle. Pre-drill holes should have a surface finish Ra ≤3.2μm to avoid thread tearing.
The Medium Carbon Steel Tip Tap is a specialized tool designed for threading cold-work tool steel (D2, A2) and gray cast iron (ASTM A48 Class 30). Its unique cutting geometry—featuring a modified rake angle (14°) and reduced land width (0.15× pitch)—is the result of finite element analysis (FEA) simulations to address the challenges of machining hard, brittle materials. Constructed from 5140 medium carbon steel (quenched to HRC 58–62 via oil cooling), it balances hardness and toughness for precision threading in tooling applications, with a fracture toughness of 12–15 MPa·m⊃1;/⊃2;.
Optimized Cutting Edge: Micro-grain carbide inserts (grain size 0.8–1.2μm) with a TiCN coating are brazed to the cutting edge using induction heating (1050°C). This enhances wear resistance in D2 steel (HRC 55–60) by 50% compared to uncoated edges.
Medium Carbon Steel Construction: Core material provides 1200 MPa tensile strength with 15% elongation, resisting fracture during interrupted cuts in cast iron with graphite flake sizes (ASTM A247) of 5–7.
Precision Thread Form: Conforms to ISO 965-1 Class 5G, ensuring interchangeability with standard tooling components (e.g., die sets with H7 tolerance bores, fixture plates with positional accuracy ±0.02mm).
Primary uses include threading injection mold cavities (P20 tool steel with surface finish Ra ≤0.8μm), engine block mounting holes (gray cast iron with 3.2–3.6% carbon content), and press tool guides (A2 steel with through-hardening). It is a staple in tool & die shops adhering to ISO 9001 manufacturing standards, where thread concentricity (≤0.03mm TIR) is critical for mold alignment.
Q: How to prevent chip breakage in cast iron?
A: Use dry machining or minimal coolant (5–10 mL/min); cast iron’s graphite content acts as a natural lubricant. For nodular cast iron (ASTM A536 60-40-18), increase feed rate by 10% to promote continuous chip formation.
Q: What is the maximum thread depth for tool steel?
A: 2× diameter for HRC 55+ material (e.g., 16mm depth for M8 tap); deeper threads require step tapping with 0.5mm incremental depth per pass to reduce cutting forces.
Q: Does it require pre-drilling?
A: Yes, use a drill bit sized to 85% of the tap diameter (e.g., 6.8mm for M8) with a 118° point angle. Pre-drill holes should have a surface finish Ra ≤3.2μm to avoid thread tearing.
